Conveyor Connection Boxes With Bus-Mounted Voltage Conversion
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Solution Overview
Problem
Conveyor systems face challenges in adapting to customer-specific requirements due to the need for integrating additional components like lifting mechanisms, locking flaps, or defectors, which are often addressed by complex and error-prone separate cabling solutions, leading to visually unappealing and costly systems.
Innovation Solution
A flexible connection system is introduced, allowing external actuators to be integrated without separate cabling, using a second connection box that is mechanically and electrically connected to the power supply bus, with adjustable voltage and power capabilities, enabling intuitive assembly and reduced system complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate cabling is used to connect additional components (lifting mechanism, locking flap, deflector) to the electrical system, then these components can be integrated into the conveyor system, but the system becomes complex, error-prone, and visually unappealing
Solution Approach 1:
The patent combines the electrical connection function with the mechanical mounting function by integrating electrical contacts directly into the connection box that attaches to the conveyor frame. This eliminates the need for separate cabling runs to control cabinets, as all electrical connections are made locally at the connection box mounted on the frame profile.
Solution Approach 2:
The connection box serves as an intermediary device that provides both mechanical support (mounting on frame profile) and electrical connection (contacts for actuators and sensors) in a single integrated component, simplifying the overall system architecture.
2Adaptability or versatility
If the initial connection boxes are extended to provide functionality for both first actuators and second actuators/sensors, then more components can be connected, but the connection box becomes technically complex and more prone to errors
Solution Approach 1:
The electrical connection system is segmented into multiple independent connection boxes, each dedicated to specific components. The first connection box handles first actuators (conveyor rollers), while the second connection box handles second actuators and sensors, avoiding the complexity of a multi-functional connection box.
Solution Approach 2:
While each connection box is specialized, the overall system achieves universality through the standardized frame profile mounting system, allowing any connection box to be positioned anywhere along the conveyor and enabling flexible configuration for different customer requirements.
3Reliability
If separate cabling is routed along the conveyor system to a control cabinet, then electrical connections can be established, but the system becomes visually unappealing and maintenance becomes difficult
Solution Approach 1:
The electrical connection function is extracted from the centralized control cabinet and distributed to local connection boxes mounted on the frame profile near the components they serve, eliminating the need for long cable runs through the conveyor structure.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A conveyor system (1, 35) for conveying unit loads is described, comprising frame profiles (2, 3, 2', 3') and a power supply bus (4, 38) arranged along the frame profile (2, 3, 2', 3'). The conveyor system (1, 35) includes a first connection box (7, 7a..7e) for the electrical connection of a first actuator (5) and a second connection box (10a..10e) for the connection of a second actuator (8, 8a, 8b), which differs from the first actuator (5) in its nominal voltage. Furthermore, a modular system is described, comprising a first connection box (7, 7a..7e) and a second connection box (10a..10e) of the aforementioned type. In particular, a voltage converter (30) is arranged in the second connection box (10a.. 10e), which provides an output AC voltage of 110 VAC and/or 230 VAC and/or 400 VAC.